Pipeline plug

ABSTRACT

A method of manufacturing a plug for a pipe system includes cutting a plug from a length of pipe, the length of pipe defining a pipe bore, the pipe bore defining an inner diameter equal to an inner diameter of a main bore of the plug, the plug including a top portion defining a top diameter, a bottom portion defining a bottom diameter, and a web portion joining the top portion and the bottom portion.

REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/702,325, filed Sep. 12, 2017, which is hereby specificallyincorporated by reference herein in its entirety.

TECHNICAL FIELD Field of Use

This disclosure relates to pipe systems. More specifically, thisdisclosure relates to plugs for pipe systems that can facilitate smoothpassage of a “pig.”

Related Art

When repairing a pipeline, it can be necessary to inhibit flow of afluid, such as natural gas or water, in the pipeline and isolate thepipeline by inserting a plug into the pipeline at a location such as,for example and without limitation, a pipeline fitting. When the repairwork is finished, the plug can be removed and a completion plug can beinstalled, sealing the fitting. Pipeline fittings used for this purposetypically require that a hole be drilled through one pipe wall oropposing walls. In either case, any hole or aperture in the pipe wallcan interfere with the travel of a “pig” through the pipeline. A pig isa device inserted into and made to travel along a pipeline to perform atask within the pipeline such as remove wall debris or assess wallthickness. According to some sources, a pig was named based on the soundit makes while traveling through a pipe system or as an acronym or“backronym” for a Pipeline Inspection Gauge. A pig that cannot passthrough the pipeline fitting and becomes lodged can be damaged or candamage the pipeline or fitting. This can result in costly repairs andcan require manual movement of the pig downstream past the area ofinterference, which can increase the cost of such work and make it moredifficult or even impossible to complete the work. A clog due to a pigthat is lodged in the pipeline can additionally result in a financialloss or major inconvenience due to users' inability to use the affectedpipeline.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

In one aspect, disclosed is a plug for a pipeline, the plug comprising:a top portion defining a top bore, the top bore defining a top diameter;a bottom portion defining a bottom bore, the bottom bore defining abottom diameter; and a web portion joining the top portion and thebottom portion; the top portion, the bottom portion, and the web portiondefining a main bore, the main bore defining a longitudinal axis of theplug and defining a circular shape around the longitudinal axis of theplug; the top portion, the bottom portion, and the web portion furtherdefining a substantially circular shape around a transverse axis of theplug that extends through the top portion and the bottom portion and isperpendicular to the longitudinal axis.

In a further aspect, disclosed is a pipe system comprising: a pipedefining an inner surface, an outer surface, and a longitudinal axis; afitting assembled on the pipe; and a plug positioned in the pipe and inthe fitting, the plug comprising: a top portion defining a top bore, thetop bore defining a top diameter; a bottom portion defining a bottombore, the bottom bore defining a bottom diameter; and wherein the topportion and the bottom portion define a main bore, the main boredefining a longitudinal axis of the plug; the plug defining asubstantially circular shape around the longitudinal axis of the plug,the longitudinal axis of the plug aligned with the longitudinal axis ofthe pipe.

In yet another aspect, disclosed is a method of manufacturing a plug fora pipe system, the method comprising: cutting a plug from a length ofpipe, the length of pipe defining a pipe bore, the pipe bore defining aninner diameter equal to an inner diameter of a main bore of the plug,the plug comprising a top portion defining a top diameter, a bottomportion defining a bottom diameter, and a web portion joining the topportion and the bottom portion; and securing stiffeners to the innerbore of the plug proximate to the web portion of the plug to reinforcethe plug at the web portion.

In yet another aspect, disclosed is a method of manufacturing a plug fora pipe system, the method comprising: cutting a plug from a length ofpipe, the length of pipe defining a pipe bore, the pipe bore defining aninner diameter equal to an inner diameter of a main bore of the plug,the plug comprising a top portion defining a top diameter, a bottomportion defining a bottom diameter, and a web portion joining the topportion and the bottom portion.

Various implementations described in the present disclosure may compriseadditional systems, methods, features, and advantages, which may notnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims. Thefeatures and advantages of such implementations may be realized andobtained by means of the systems, methods, features particularly pointedout in the appended claims. These and other features will become morefully apparent from the following description and appended claims, ormay be learned by the practice of such exemplary implementations as setforth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several aspects of the disclosureand together with the description, serve to explain various principlesof the disclosure. The drawings are not necessarily drawn to scale.Corresponding features and components throughout the figures may bedesignated by matching reference characters for the sake of consistencyand clarity.

FIG. 1 is a sectional view of a pipe system comprising a pipe and afitting in accordance with one aspect of the current disclosure andtaken along line 1-1 of FIG. 2 but with a cap and cap fasteners of thefitting removed.

FIG. 2 is perspective view of the system of FIG. 1 further comprising apig passing through a plug installed inside the fitting.

FIG. 3 is a side view of the plug of FIG. 2.

FIG. 4 is a top view of the plug of FIG. 2.

FIG. 5 is a top view of the plug of FIG. 2 in accordance with anotheraspect of the current disclosure.

FIG. 6 is a front view of the plug of FIG. 2.

FIG. 7 is a sectional view of the plug of FIG. 2 taken along line 7-7 ofFIG. 6.

FIG. 8 is a perspective view of the plug of FIG. 2 in an unassembledstate.

FIG. 9 is a perspective view of the plug of FIG. 8 in accordance withanother aspect of the current disclosure.

FIG. 10 is a top view of the plug of FIG. 9.

FIG. 11 is a bottom view of the plug of FIG. 9.

FIG. 12 is a perspective view of the plug of FIG. 8 in accordance withanother aspect of the current disclosure.

FIG. 13 is a sectional view of the plug of FIG. 12 taken along line13-13 of FIG. 12.

FIG. 14 is a sectional view of the system of FIG. 2 taken along line 1-1of FIG. 2 and further comprising the plug of FIG. 2 as installed.

FIG. 15 is a sectional view of the system of FIG. 2 in accordance withanother aspect of the current disclosure taken along line 1-1 of FIG. 2and further comprising the plug of FIG. 9 as installed.

FIG. 16 is a front perspective view of the plug of FIG. 2 mounted on aplug installation tool.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference tothe following detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this disclosure is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,as such can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of thepresent devices, systems, and/or methods in their best, currently knownaspect. To this end, those skilled in the relevant art will recognizeand appreciate that many changes can be made to the various aspectsdescribed herein, while still obtaining the beneficial results of thepresent disclosure. It will also be apparent that some of the desiredbenefits of the present disclosure can be obtained by selecting some ofthe features of the present disclosure without utilizing other features.Accordingly, those who work in the art will recognize that manymodifications and adaptations to the present disclosure are possible andcan even be desirable in certain circumstances and are a part of thepresent disclosure. Thus, the following description is provided asillustrative of the principles of the present disclosure and not inlimitation thereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to a quantity of one of a particular element cancomprise two or more such elements unless the context indicatesotherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect comprises from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about” or substantially,” itwill be understood that the particular value forms another aspect. Itwill be further understood that the endpoints of each of the ranges aresignificant both in relation to the other endpoint, and independently ofthe other endpoint.

For purposes of the current disclosure, a material property or dimensionmeasuring about X or substantially X on a particular measurement scalemeasures within a range between X plus an industry-standard uppertolerance for the specified measurement and X minus an industry-standardlower tolerance for the specified measurement. Because tolerances canvary between different materials, processes and between differentmodels, the tolerance for a particular measurement of a particularcomponent can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description comprises instances where said event orcircumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also comprises any combination of members of that list.

To simplify the description of various elements disclosed herein, theconventions of “left,” “right,” “front,” “rear,” “top,” “bottom,”“upper,” “lower,” “inside,” “outside,” “inboard,” “outboard,”“horizontal,” and/or “vertical” may be referenced. Unless statedotherwise, “front” describes that axial end of the structural element,e.g., a plug or a fitting, that is positioned downstream and distal fromthe upstream end or inlet; “rear” is that end of the plug or the fittingthat is opposite or distal the front; “left” is that which is to theleft of or facing left from a person facing towards the front whilelooking upstream along the central axis of the plug or the fitting; and“right” is that which is to the right of or facing right from that sameperson. “Horizontal” or “horizontal orientation” describes that which isin a plane extending from left to right and aligned with the horizon.“Vertical” or “vertical orientation” describes that which is in a planethat is angled at 90 degrees to the horizontal.

In one aspect of the current disclosure, a plug for a pipe system andassociated methods, systems, devices, and various apparatuses aredisclosed herein. The plug can be fabricated from a similar or identicalmaterial or similar or identical dimensions as the pipe in which it ispositioned. The plug can comprise a positioning member.

As shown in FIG. 1, a pipe system 50, which can comprise a pipeline thatcan comprise individual pipes such as a pipe 100, can be used toefficiently transfer fluids such as, for example and without limitation,natural gas over a distance from a first location to a second location.Over time, however, waste can build up inside the pipes 100 of the pipesystem 50. Additionally, a pipe wall of the pipes 100 can begin todeteriorate depending on the installation environment or the fluid beingtransported. When this occurs or to determine whether this has occurred,a “pig” 200 (shown in FIG. 2) can be inserted into the pipe system 50 toclean the walls of the pipe 100 or to inspect the pipe system 50 (e.g.,to assess a pipe wall thickness 108 in a radial direction relative to alongitudinal axis 103 of the pipe 100 and/or to check for deformation ofthe pipe 100). The pig 200 itself can be driven by the fluid flowinginside the pipe system 50.

As shown in FIG. 1, the pipe 100 of the pipe system 50 can define aninner surface 101 and an outer surface 102 and can define apertures inthese surfaces at various points along the length of the pipe 100. Suchapertures can be positioned, for example and without limitation,proximate to or aligned with a fitting 150 of the pipe system 50 and canextend from the inner surface 101 to the outer surface 102 to allowaccess into the pipe 100. For example and without limitation, the pipe100 can define a top aperture 110 and a bottom aperture 120 that eachextend from the inner surface 101 to the outer surface 102. The fitting150, which can be a stopping fitting, can comprise a completion plug 160that closes and seals a top opening 180 of the fitting 150 and a cap 170that closes and seals a bottom opening 190 of the fitting 150. The pipe100 can further define a pipe bore 105 defining an inner diameter 109.

The pipe 100 can define a transverse axis 104, each of the top aperture110 and the bottom aperture 120 can define respective transverse axes114,125, and the fitting 150 can define a transverse axis 154. Proximateto where the top aperture 110 and the bottom aperture 120 are defined inthe pipe 100, the pipe 100 can further define a web portion 130extending between the top aperture 110 and the bottom aperture 120. Theweb portion 130 can define a thickness in a radial direction relative tothe longitudinal axis 103 of the pipe 100 that is less than the pipewall thickness 108 and can be formed when the pipe 100 is cut to formthe top aperture 110 and the bottom aperture 120, e.g., by a shellcutter known in the art. In some aspects, as shown, the transverse axes104, 114, 124, 154 can all be aligned with each other. In other aspects,the transverse axes 104, 114, 124, 154 need not be aligned with eachother or only some of the transverse axes 104, 114, 124, 154 can bealigned with each other.

When the pig 200 is traveling through the pipe system 50 through andpast the top aperture 110 and the bottom aperture 120, a longitudinalaxis 203 (shown in FIG. 2) of the pig 200 can fall off or otherwisebecome misaligned with the longitudinal axis 103 of the pipe 100, atleast if there is no pipe wall to guide the pig 200 at the top aperture110 and the bottom aperture 120. Upon misalignment of the pig 200 withthe longitudinal axis 103, the pig 200 can become lodged or stuck in thefitting 150. Additionally, sensors (not shown) attached to the pig 200or other parts of the pig 200 can be damaged or even destroyed by theedges of the top aperture 110 or the bottom aperture 120, which can besharp. A lodged or damaged pig 200 can result in at least a portion ofthe pipe system 50 becoming damaged or unavailable, which can furtherresult in a potential loss of profits or other benefits that wouldotherwise be available from smooth operation of the pipe system 50.

As shown in FIG. 2, a plug 300 can facilitate free travel of the pig 200through the pipe system 50, especially where apertures such as the topaperture 110 and the bottom aperture 120 are defined in the pipe 100such as at the fitting 150. The plug 300 can define a longitudinal axis303 and a transverse axis 304. The transverse axis 304 can intersect thelongitudinal axis 303 at a 90-degree angle.

FIG. 3 shows the plug 300. The plug 300 can define an inner surface 301(shown in FIG. 4) and an outer surface 302. The plug 300 can comprise atop portion 310 defining a top bore 315 (shown in FIG. 4), which candefine a bore diameter 318 (shown in FIG. 7), measured as shown. Theplug 300 can comprise a bottom portion 320 defining a bottom bore 325(shown in FIG. 4), which can define a bore diameter 328 (shown in FIG.7), measured as shown. The plug 300 can comprise a web portion 330,which can join the top portion 310 and the bottom portion 320. The topportion 310 can further define a top diameter 319, which can be equal toan axial length at the top of the plug 300. The bottom portion 320 canfurther define a bottom diameter 329 (shown in FIG. 11) and an axiallength 327. In some aspects, the bottom portion 320 can define truncatedends 380 a,b. The bottom diameter 329 can be greater than the axiallength 327 of the top portion 310, including when the truncated ends 380a,b are present. In other aspects, the bottom diameter 329 can be equalto the axial length 327. The outer surface 302 can define an edge 312 ofthe top portion 310, which can define an intersection between the topportion 310 and the web portion 330. Likewise, the outer surface 302 candefine an edge 322 of the bottom portion 320, which can define anintersection between the bottom portion 320 and the web portion 330. Asdescribed below, the web portion 330 can define a thickness in a radialdirection relative to the longitudinal axis 303 that is less than athickness 708 (shown in FIG. 7) of the top portion 310 of the plug 300in the radial direction relative to the longitudinal axis 303. Thebottom portion 320 defines a thickness in the radial direction relativeto the longitudinal axis 303 that can be equal to thickness 708. The webportion 330—together with the edges 312,322—can be formed when the plug300 is cut from the pipe 100 with a substantially vertical cutting tool.In another aspect, the web portion 330—together with the edges312,322—can be formed when the plug 300 is cut from the pipe 100 with acutting tool that is angled at 90 degrees with respect to thelongitudinal axis 103 of the pipe 100.

In some aspects, the size and shape of the top portion 310, includingwhen viewed from the side (as in FIG. 3) and from the top (as in FIG.4), can approximately match the size and shape of the top aperture 110in the pipe 100. Likewise, in some aspects, the size and shape of thebottom portion 320, including when viewed from the side (as in FIG. 3)and from the bottom (as in FIG. 11), can approximately match the sizeand shape of the bottom aperture 120 in the pipe 100. The shape can beparabolic from the side and circular from the top or bottom. In otheraspects, each of the top portion 310 and the bottom portion 320 can bemade slightly smaller to account for manufacturing or installationtolerances that can necessitate a looser fit between the plug 300 andthe pipe 100.

The plug 300 can further comprise a spring boss 350, which can besecured to the top portion 310. An axis 354 of the spring boss 350 canbe aligned with the transverse axis 304 of the plug 300. The spring boss350 can define a biasing element restraint 353, which can comprise anannular groove. The biasing element restraint 553 can be defined in anouter surface of the spring boss 350. The spring boss 350 can be securedto the outer surface 302 of the plug 300 by any suitable method such as,for example and without limitation, welding, threading, or press fits.

The plug 300 can further comprise a plug boss 360, which can be securedto the bottom portion 320. An axis 364 of the plug boss 360 can bealigned with the transverse axis 304 of the plug 300. The plug boss 360can be secured to the outer surface 302 of the plug 300 by any suitablemethod such as, for example and without limitation, welding, threading,or press fits.

The plug 300 can comprise positioning members 370 a, b, c, d (370 c,dshown in FIG. 4), which can help fix the vertical position of the plug300 in the pipe 100. In one aspect, each of the positioning members 370a, b, c, d can be secured to the outer surface 302 of the top portion310. Each of the positioning members 370 a, b, c, d can extend beyondthe edge relative to the transverse axis or beyond the top diameter 319of the top portion 310 of the plug 300 by an extension distance 410(shown in FIG. 4). In some aspects, each of the positioning members 370a, b, c, d can be shaped like a flat washer and can be fastened to thetop portion 310 by a corresponding fastener 390 a, b, c, d (390 c,dshown in FIG. 4).

In other aspects, as shown in FIG. 5, each of the positioning members370 a, b, c, d can comprise a bar, a plate, or another rigid shape,which can be fastened to the outer surface 302 of the top portion 310 ofthe plug 300 using any fastening method such as, for example and withoutlimitation, a weldment or an adhesive. In yet other aspects, thematerial of the top portion 310 of the plug 300 can be formed into aplurality of steps (not shown) with a distance from the inner surface301 of the plug 300 to an inner surface (i.e., radially inward facingsurface) of the step equal to the pipe wall thickness 108 of the pipe100 but having the same function as the positioning members 370 a, b, c,d. In yet other aspects, the inner surface 301 of the plug 300 can bemachined or notched or otherwise formed, optionally in combination withthe aforementioned step, to create a ledge or flange on the plug 300that is configured to positively locate the top portion 310 of the plug300 relative to the pipe 100 such that that the longitudinal axis 303 ofthe plug 300 is aligned with the longitudinal axis 103 of the pipe 100.More specifically, each of the positioning members 370 a, b, c, d can beconfigured to rest on the outer surface 302 of the pipe 100 when a mainbore 340 (shown in FIG. 6) of the plug 300 is aligned with thelongitudinal axis 103 of the pipe 100. As shown, the spring boss 350 candefine a spring boss bore 355.

As shown in FIG. 6, the top portion 310, the bottom portion 320, and theweb portion 330 can define the main bore 340 of the plug 300. The mainbore 340 can define the longitudinal axis 303 of the plug 300 and candefine a circular shape around the longitudinal axis 303 of the plug 300in cross section and when viewing the plug 300 from the front, which candefine an inner diameter 601. The inner diameter 601 of the main bore340 of the plug 300 can be made substantially equal to the innerdiameter 129 of the pipe 100.

The plug 300 can further define an outer diameter 602 as shown. Each ofthe top portion 310 and the bottom portion 320 can separately define asemicircular shape in cross-section and when viewing the plug 300 fromthe front.

In some aspects, as shown, each of the positioning members 370 a, b, c,d can be positioned at a point on a circumference of the outer surface302 of the top portion 310 of the plug 300 that is angled from thetransverse axis 304 of the plug 300 by an angle 690 of 30 degrees. Inother aspects, the angle 690 can be greater than or less than 30degrees.

A thickness 708 (shown in FIG. 7) of a wall of the plug 300 in a radialdirection relative to the longitudinal axis 303 can be reduced at theweb portion 330 to a minimum thickness 630. More specifically, at eachof a pair of web portion halves 330 a,b the thickness of the plug 300can be the minimum thickness 630. In one aspect, to compensate for thereduced thickness of the plug 300 at the web portion 330 (and webportion halves 330 a,b), stiffeners 610 a,b can be secured to the innersurface 301 of the plug 300, such as by welding or with adhesives. Thestiffeners 610 a,b can be used to reinforce the connection between thetop portion 310, the bottom portion 320, and the web portion 330. Eachof the stiffeners 610 a,b can be a plate secured to the inner surface301 of the main bore 340 of the plug 300. A top of each of thestiffeners 610 a,b can be made to extend a vertical distance 616 fromthe longitudinal axis 303 of the plug 300, which can result in each ofthe stiffeners 610 a,b extending a vertical distance 613 above thelowest part of the edge 312 (shown in FIG. 3) and a vertical distance614 below the highest part of the edge 322 (shown in FIG. 3). In anotheraspect, as described below with respect to FIGS. 12 and 13, a stiffener610 can be integrally formed from walls of the plug 300.

As shown in FIG. 6, the plug 300 can be tapered along the transverseaxis 304. As reflected in FIG. 11, this taper can result in the topdiameter 319 of the plug 300 being greater than the bottom diameter 329of the plug 300. Likewise, a diameter of the top aperture 110 of thepipe 100 can be made greater than a diameter of the bottom aperture 120of the pipe 100. A taper angle 680 can be defined relative to thetransverse axis 304 and can define a taper starting at a verticaldistance 618 below the longitudinal axis 303 of the plug 300. In someaspects, the angle 680 can be 5 degrees. In other aspects, the taperangle 680 can be greater than or less than 5 degrees. Also reflectingthis taper, a top width 619 of the plug 300, which is a maximum width ofthe top portion 310 when viewed from the front, can be made larger thana bottom width 629 of the plug 300, which is a maximum width of thebottom portion 320 when viewed from the front. In some aspects, asshown, the top width 619 can also be a maximum outer width of the webportion 330 when viewed from the front and the bottom width 629 can alsobe a minimum outer width of the web portion 330 when viewed from thefront.

FIG. 7 shows a sectional view of the plug 300. The plug 300 can define aplurality of holes 790 a, b, c, d (790 a,b shown in FIG. 8), which canbe sized to receive the respective fasteners 390 a, b, c, d. A width ofthe stiffener 610 a,b can be made equal to a width of the correspondingweb portion half 330 a. The top bore 315 can define the bore diameter318, and the spring boss 350 can define the spring boss bore 355, whichcan define a bore diameter 358 and an outer boss diameter 359. Likewise,the bottom bore 325 can define the bore diameter 328, and the plug boss360 can define the plug boss bore 365, which can define a bore diameter368 and an outer boss diameter 369.

In various aspects, FIGS. 8 and 9 show the plug 300 without the springboss 350, the plug boss 360, the positioning members 370 a, b, c, d, orthe stiffeners 610 a,b. The top bore 315 can be aligned with the bottombore 325 along the transverse axis 304. As shown in FIG. 9, each of thetop portion 310 and the bottom portion 320 can define a plurality offlow bores 910,920, respectively, which as described below can permitflow of fluid in the fluid system through the top portion 310 and thebottom portion 320 of the plug 300 into, e.g., the fitting 150 or abranch line 1300 (shown in FIG. 15) of the pipe system 50. Each of theplurality of flow bores 910,920 can be made to extend from an outersurface 302 of the plug 300 to an inner surface 301 of the plug 300.

As shown in FIG. 10, each of the flow bores 910 can define a diameter918. Likewise, as shown in FIG. 11, each of the flow bores 920 candefine a diameter 928. In some aspects, as shown in FIG. 10, each of theflow bores 910 (or, in other aspects, the flow bores 920) can bearranged in a circular pattern defining a pattern diameter 919. In otheraspects, as shown in FIG. 11, each of the flow bores 920 (or, in otheraspects, the flow bores 910) can be arranged in rows such that the flowbores 920 are staggered as shown to maximize open area. In yet otheraspects, the flow bores 910,920 can be arranged in any other patternsuch as, for example and without limitation, multiple circular patterns,flow bores 910,920 having different diameters, and partially overlappingflow bores 910,920. The flow bores 910,920 can define a non-circularshape such as an elongated slot or a rectangular or other opening inother aspects. The flow bores 910,920 can be arranged without or withoutstaggering. In yet other aspects, the flow bores 910,920 can be arrangedwithout any identifiable pattern. In some aspects, as shown, the borehole surfaces of the flow bores 910,920 can be formed in a directionparallel to the transverse axis 304 (i.e., vertically). In otheraspects, the bore hole surfaces of the flow bores 910,920 can be formedperpendicular to a portion of the inner surface 301 or the outer surface302 in which the respective flow bore 910,920 is defined. As shown inboth FIGS. 10 and 11, the top portion 310, the bottom portion 320, andthe web portion 330 can define a substantially circular shape around thetransverse axis 304 of the plug 300.

As shown in FIG. 11, the truncated ends 380 a,b of the bottom portion320 can define edges 385 a,b offset a distance 1100 from the otherwisecircular shape of the bottom portion 320 formed by the bottom diameter329. In one aspect, as shown, each of the edges 385 a,b can be flat orstraight. In another aspect, each of the edges 385 a,b can be curvedsuch one or both of the edges 385 a,b can be closer to or further fromthe bottom diameter 329.

FIGS. 12 and 13 show a plug, again without the spring boss 350, the plugboss 360, or the positioning members 370 a, b, c, d. As shown, astiffener 610 can be formed from the walls of the plug 300. In oneaspect, a plug wall with the original thickness 708 can be machined ateach axial end of the plug such that the plug 300 including thestiffener 610 is monolithic. Machining various versions of the plug 300from a pipe material having a common thickness 708 to form an integralstiffener 610 can have the benefit of reduced inventory of the pipematerial used to form the various versions of the plug 300 and provideflexibility for a wider variety of sizes. For example and withoutlimitation, the thickness 708 of the pipe material used to form the plugcan be as much as 0.375″ or greater. In another aspect, the plug 300 canbe formed with the integral stiffener 610 without machining by a processsuch as, for example and without limitation, casting or molding. Onceformed, as shown in FIG. 13, the stiffener 610 can define a stiffenerheight 1350 measured from a radially outermost portion of the innersurface 301 of the plug 300. The stiffener 610 can further define edgetreatments 612, each of which can be a chamfer defining a surface angledwith respect to the inner surface 301 in cross-section as shown by anangle 1320.

FIGS. 14 and 15 show two aspects of the pipe system 50 comprising theplug 300 positioned inside the fitting 150. FIG. 14 specifically showsthe plug 300 without the flow bores 910,920 positioned inside thefitting 150, while FIG. 15 shows the plug 300 with the flow bores910,920. A biasing assembly 1200 comprising a biasing element 1210 and acap 1220 can be positioned between the top portion 310 of the plug 300and the completion plug 160 to bias the plug 300 towards its alignedposition in the pipe 100. A first end of the biasing element 1210 can becaptured inside the groove 353 (shown in FIG. 6) of the spring boss 350(shown in FIG. 6), while a second end of the biasing element 1210 can becaptured inside the cap 1220. In other aspects, the biasing element 1210can directly contact the outer surface 302 of the plug 300 and candirectly contact a surface of the completion plug 160.

The biasing element 1210 can hold the plug 300 in alignment with thepipe 100 with a compression force induced by contact of the completionplug 160 with the biasing element 1210. In some aspects, the biasingelement 1210 can be a coil spring. In other aspects, the biasing element1210 can be another type of spring such as, for example and withoutlimitation, a leaf spring, a wave spring, or any other compressiblematerial or device. As shown, when the plug 300 is in its alignedposition, the inner surface 301 of the plug 300 can be made to sit flushwith the inner surface 101 of the pipe 100 around the circumference ofthe inner surface 301 of the plug 300. Flush alignment between the innersurface 301 of the plug 300 and the inner surface 101 of the pipe 100can facilitate passage of the pig 200 through the pipe 100, includingwhere the plug 300 is installed in the fitting 150. The presence of thestiffeners 610, which have a thickness and can extend radially inwardfrom the inner surface 301 of the plug 300, do not interfere with thepig 200 because of their relatively low profile. In some aspects, one ormore edges of the stiffeners 610 can be rounded or chamfered in axialdirections relative to the longitudinal axis 303 to further facilitatepassage of the pig.

FIG. 15 shows the pipe system 50 further comprising the branch line 1300extending from the fitting 150 in a direction angled with respect to thelongitudinal axis 103 of the pipe 100 and the plug 300 defining aplurality of flow bores 910,920 in a portion of the plug 300 facing thebranch line 1300.

FIG. 16 shows a plug 300 assembled to a plug installation tool 1400 inpreparation for installation of the plug 300 into the pipe system 50.The plug installation tool 1400 can comprise a body 1420 with handles1440 and a flange 1430. When an axis 1404 of the plug installation tool1400 is aligned with the transverse axis 304 of the plug 300, anassembly shaft 1410 of the plug installation tool 1400 can be insertedinto the plug 300. More specifically, an end portion 1412 of theassembly shaft 1410 can be configured to fit inside the plug boss 360 asshown and a shoulder portion 1416 of the assembly shaft 1410 can beconfigured to fit inside the spring boss 350. A middle portion 1414 ofthe assembly shaft 1410 can join the end portion 1412 and the shoulderportion 1416. During installation, with the plug 300 assembled aroundthe assembly shaft 1410 of the plug installation tool 1400, thetransverse axis 304 of the plug 300 can be aligned with the transverseaxis 104 of the pipe 100 and the plug 300 inserted into the pipe 100 inorder to position the plug 300 into the fitting and into the pipe 100.As desired, the flange 1430 of the plug installation tool 1400 can beused to mount the plug installation tool 1400 to the fitting 150.

In other aspects, the pipe 100 can define only a top aperture 110 andthe plug 300 can comprise only the top portion 310 and optionally atleast a portion of the web portion 330. For example and withoutlimitation, a shell cutter or other tool can be used to cut an openingsuch as the top aperture 110 in only one side of the pipe 100, in whichcase a smaller plug without a bottom portion 320 can be sufficient toplug the only opening, the top aperture 110. In yet other aspects, thepipe 100 can define only a bottom aperture 120 and the plug 300 cancomprise only the bottom portion 320 and optionally at least a portionof the web portion 330. In some aspects, the plug 300 can be installedfrom the top. In other aspects, the plug 300 can be installed from thebottom.

In some aspects, the plug 300 can be formed from metal and specificallycan be formed from the same material from which the pipe 100 is formed.In other aspects, the plug 300 can comprise another material such as,for example and without limitation, a plastic or a ceramic. A materialsuch as used in the plug 300 can exhibit a variety of mechanicalproperties including a yield strength. In some aspects, the yieldstrength in tension of the material is equal to between 48,000 and80,000 psi (between approximately 331 MPa and approximately 552 MPa).The plug 300 can be a monolithic piece of material, i.e., the plug 300can be formed from or into a single piece of material. In some aspects,as shown, the plug 300 is installed in both the pipe 100 and in thefitting 150. In other aspects, the plug 300 is only installed in thepipe 100.

A method of manufacturing the plug 300 for the pipe system 50 cancomprise cutting a plug 300 from a length of pipe material used to formthe pipe 100. In some aspects, cutting the plug 300 can comprise cuttingwith an electrical discharge machining (EDM) process. Cutting the plug300 can comprise cutting the top diameter 319 of the plug 300 greaterthan the bottom diameter 329 of the plug 300.

The method can further comprise securing stiffeners 610 a,b to the mainbore 340 of the plug 300 proximate to the web portion of the plug 300 toreinforce the plug 300 at the web portion 330. The method can furthercomprise securing a plurality of positioning members 370 a, b, c, d toan outer surface 302 of the top portion 310 of the plug 300.

One should note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily comprise logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular aspect.

It should be emphasized that the above-described aspects are merelypossible examples of implementations, merely set forth for a clearunderstanding of the principles of the present disclosure. Any processdescriptions or blocks in flow diagrams should be understood asrepresenting modules, segments, or portions of code which comprise oneor more executable instructions for implementing specific logicalfunctions or steps in the process, and alternate implementations areincluded in which functions may not be included or executed at all, maybe executed out of order from that shown or discussed, includingsubstantially concurrently or in reverse order, depending on thefunctionality involved, as would be understood by those reasonablyskilled in the art of the present disclosure. Many variations andmodifications may be made to the above-described aspect(s) withoutdeparting substantially from the spirit and principles of the presentdisclosure. Further, the scope of the present disclosure is intended tocover any and all combinations and sub-combinations of all elements,features, and aspects discussed above. All such modifications andvariations are intended to be included herein within the scope of thepresent disclosure, and all possible claims to individual aspects orcombinations of elements or steps are intended to be supported by thepresent disclosure.

That which is claimed is:
 1. A method of manufacturing a plug for a pipesystem, the method comprising: cutting a plug from a length of pipe, thelength of pipe defining a pipe bore, the pipe bore defining an innerdiameter equal to an inner diameter of a main bore of the plug, the plugcomprising a top portion defining a top diameter, a bottom portiondefining a bottom diameter, and a web portion joining the top portionand the bottom portion.
 2. The method of claim 1, further comprisingforming a stiffener in the main bore of the plug proximate to the webportion of the plug to reinforce the plug at the web portion.
 3. Themethod of claim 2, wherein forming the stiffener comprises forming thestiffener separately from the plug and securing the stiffener to theplug.
 4. The method of claim 1, further comprising forming a pluralityof plug bores in a one of the top portion and the bottom portion.
 5. Themethod of claim 4, wherein each of the plurality of plug bores extendsfrom an outer surface of the plug to an interior surface of the plug. 6.The method of claim 4, wherein each of the plurality of plug bores iscircular.
 7. The method of claim 4, wherein the plurality of plug boresdefines a pattern.
 8. The method of claim 1, wherein cutting the plugcomprises cutting the plug with an electrical discharge machining (EDM)process.
 9. The method of claim 1, wherein cutting the plug comprisescutting the plug from metal.
 10. The method of claim 1, wherein cuttingthe plug comprises cutting the top diameter of the plug greater than thebottom diameter of the plug.
 11. The method of claim 1, furthercomprising securing a plurality of positioning members to an outersurface of the top portion of the plug.
 12. The method of claim 11,wherein securing the plurality of positioning members comprises weldingeach of the positioning members to the outer surface of the top portion.13. The method of claim 11, wherein securing the plurality ofpositioning members comprises securing each of the positioning membersto the outer surface of the top portion with a fastener.
 14. The methodof claim 11, wherein securing the plurality of positioning memberscomprises positioning each of the positioning members to extend beyondthe edge of the top portion of the top portion by an extension distance.15. The method of claim 1, further comprising forming a top bore in thetop portion.
 16. The method of claim 1, further comprising forming abottom bore in the bottom portion.
 17. The method of claim 1, furthercomprising securing a spring boss to the top portion.
 18. The method ofclaim 17, wherein securing the spring boss to the top portion compriseswelding the spring boss to the top portion.
 19. The method of claim 1,further comprising securing a plug boss to the bottom portion.
 20. Themethod of claim 19, wherein securing the plug boss to the bottom portioncomprises welding the plug boss to the bottom portion.